Micro-channeled protective film

Abstract

The present invention relates to a film comprising a backing and an adhesive. The backing comprises a base layer comprising a first major surface and a second major surface, and at least two rails, each rail comprising a tip surface. The rails extend from the second major surface of the base layer and define micro-channels therebetween. The micro-channels comprise a channel surface. The film comprises an adhesive on the tip surface of the rails. At least a portion of the channel surface is substantially free of adhesive. The present invention also relates to a method of protecting an automobile comprising preparing an automobile surface for application of a protective tape and applying a protective tape to the automobile surface. The present invention is additionally related to a method of manufacturing a protective film.

What is claimed is:  
     
       1. A film comprising 
       a backing comprising  
       a base layer comprising a first major surface and a second major surface; and  
       at least two rails, each rail comprising a tip surface, the rails extending from the second major surface of the base layer and defining micro-channels therebetween, the micro-channels comprising a channel surface; and  
       an adhesive on the tip surface of the rails,  
       at least a portion of the channel surface being substantially free of adhesive.  
     
     
       2. The film of  claim 1  wherein the width of the rails is between about 0.03 to about 5.0 millimeter. 
     
     
       3. The film of  claim 1  wherein the width of the rails is between about 0.05 and about 0.5 millimeter. 
     
     
       4. The film of  claim 1  wherein the distance between the rail tip surface and the second major surface of the backing is between about 0.03 to about 2.5 millimeter. 
     
     
       5. The film of  claim 1  wherein the distance between the rail tip surface and the second major surface of the backing is between about 0.1 to about 1.3 millimeter. 
     
     
       6. The film of  claim 1  wherein the rails have side surfaces and the distance between adjacent rail side surfaces is between about 0.05 to about 5.0 millimeter. 
     
     
       7. The film of  claim 6  wherein the distance between adjacent rail side surfaces is between about 0.3 to about 1 millimeter. 
     
     
       8. The film of  claim 1  wherein the base layer is between about 0.003 and about 12.7 millimeters thick. 
     
     
       9. The film of  claim 1  wherein the base layer is between about 0.03 and about 0.13 millimeters thick. 
     
     
       10. The film of  claim 1  wherein the backing is multilayer. 
     
     
       11. The film of  claim 1  wherein the base layer is multilayer. 
     
     
       12. The film of  claim 1  wherein the rails are multilayer. 
     
     
       13. The film of  claim 1  wherein the base layer comprises a first material and the rails comprise a second material, the first material being different from the second material. 
     
     
       14. The film of  claim 13  wherein the base layer comprises a polypropylene or copolymer thereof and the rails comprise a thermoplastic elastomer or a thermoplastic polyolefin. 
     
     
       15. The film of  claim 1  wherein the rails comprise a polymeric material that softens below 80° C. 
     
     
       16. The film of  claim 1  wherein the rails extend in a substantially parallel relationship with respect to one another in a single direction along the base layer, each rail being substantially continuous along the entire length of the base layer. 
     
     
       17. The film of  claim 1  wherein the rails extend in a substantially parallel relationship with respect to one another in a single direction along the base layer, each rail being substantially discontinuous along the entire length of the base layer. 
     
     
       18. The film of  claim 1  wherein the second major surface of the base layer is substantially free of adhesive. 
     
     
       19. The film of  claim 1  wherein the rails have a side surface, and the side surface is substantially free of adhesive. 
     
     
       20. A method of protecting an automobile comprising 
       preparing an automobile surface for application of a protective tape;  
       applying a protective tape to the automobile surface, the protective tape comprising  
       a backing comprising  
       a base layer comprising a first major surface and a second major surface; and  
       at least two rails comprising a tip surface, the rails extending from the second major surface of the base layer, the rails defining micro-channels therebetween, the micro-channels comprising a channel surface; and  
       an adhesive on the tip surface of the rails.  
     
     
       21. The method of  claim 20  further comprising exposing the protective tape to an elevated temperature after applying the protective tape to the automobile surface to soften the rails and cause them to flow together to thereby partially or completely eliminate the micro-channels. 
     
     
       22. A method of manufacturing a protective film comprising 
       providing at least one film forming material;  
       providing an adhesive material;  
       feeding the film forming material and the adhesive material into an extrusion process having a die, wherein the die has a profile; and  
       simultaneously extruding the adhesive material and the film forming material through the die to create micro-channels in the film forming material.